Dairy product and process

ABSTRACT

The invention provides a novel process of making cheese comprising the production of a coagulum which is caused to disaggregate into small curd particles in an in-line continuous flow process, separation of the curd particles from the whey and subsequent heating and mechanical working of the curd particles into a cheese mass.

REFERENCE TO RELATED APPLICATIONS

The present application is the U.S. National phase of internationalapplication number PCT/NZ03/000027, filed Feb. 18, 2003, and claimspriority under 35 U.S.C. §119 to New Zealand application number 517293,filed Feb. 19, 2002 and New Zealand application number 521690, filedSep. 30, 2002.

FIELD OF THE INVENTION

The present invention relates to a novel process of making cheese and toa cheese product made by said process.

BACKGROUND OF THE INVENTION

Traditional cheesemaking processes typically form a coagulum by theaddition of an enzyme that sets a vat of cheesemilk. The coagulum isthen mechanically cut to form curd particles which allow syneresis tooccur.

In this traditional vat setting and cutting process considerablevariability in the curd characteristics can occur resulting in impairedproduct consistency such that compositional and functionalcharacteristics of the final cheese may not fall within the standardsacceptable by the industry or consumer.

In particular, texture, melt and flavour characteristics are importantcheese characteristics. Any method of cheese making that can reduce thevariability and criticality of one of the traditional cheese makingsteps, yet maintain flexibility in the functional characteristics of theend cheese product, gives the cheese making industry a way of producinga cheese having the required functional characteristics in a consistentmanner. This is beneficial to the cheese making industry, largeconsumers such as the pizza industry, as well as individual consumers.

It is an object of the present invention to provide such a processand/or at least to provide the public with a useful choice.

SUMMARY OF THE INVENTION

The present invention provides a process of manufacturing cheese wherebythe traditional step of producing a solid coagulated mass of protein ora coagulum from a protein containing starting milk, which requirescutting to aid separation of the curd from the whey, is replaced with astep whereby such a coagulated mass is caused to disaggregate into smallcurd particles without mechanical cutting and whereby the curd particlesare separated from the whey by simple screen sieving or mechanicalseparation. The production of such curd particles provides a morereliable and consistent curd for cheese making in general. The curdproduced by the present invention is then heated and mechanically worked(stretched) such as in traditional mozzarella cheese making processes byeither immersing the curd in hot water or heating and working in asubstantially liquid-free environment. Moreover, a range of cheeses maybe made by this method including but not limited to cheddar,cheddar-like, gouda, gouda-like, as well as mozzarella andmozzarella-like (pizza) cheeses. The term mozzarella in this documentincludes the generic range of mozzarella cheese types including standardfat and moisture mozzarella, part-skimmed mozzarella and low-moisturemozzarella.

Other GRAS (Generally Regarded As Safe) ingredients common to cheesemaking process may be added at any suitable stage of the above mentionedprocesses to alter any functional characteristic or improve flavour,texture, colour and the like, as would be understood by a person ofskill in the art.

The present invention is also directed to a cheese including a soft,semi-soft, hard and extra hard cheese produced by a process according tothe invention. Preferred cheeses include cheddar, cheddar-like, gouda,gouda-like, mozzarella and mozzarella-like cheeses. By mozzarella andmozzarella-like (pizza) cheese is meant a cheese made using a process ofthe present invention, which has stringy characteristics on melting.

DESCRIPTION OF THE FIGURES

The present invention will now be described with reference to thefigures of the accompanying drawings in which:

FIG. 1 shows a schematic drawing of the process of a preferredembodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides an alternative process of making a cheesehaving consistent compositional and functional characteristics, such asmelt and sensory characteristics.

In particular it is an advantage of the present invention that theformation of the coagulum and its subsequent disaggregation into curdsand whey is conducted as an in-line, continuous flow process that doesnot require vat setting or mechanical cutting of the coagulum.

Specifically, the novel process of the present invention comprises thecontinuous production of small curd particles in place of the vats ofcoagulated cheesemilk produced in traditional cheese making processes,in combination with a mechanical processing step whereby the curdparticles are heated and worked into a cheese mass in accordance withthe traditional mozzarella-type cheese making process.

Surprisingly, cheeses of all types, including soft, semi-soft, hard andextra hard such as cheddar, cheddar-like, gouda, gouda-like, as well asmozzarella and mozzarella-like cheeses may be made by this novelprocess.

The advantages of the novel process of the present invention include theability to closely control the functional and compositionalcharacteristics of the end cheese products to enable the consistentproduction of cheeses having enhanced functional and compositionalcharacteristics. In particular, this process allows for the productionof cheeses having a higher moisture and lower calcium content than maybe achieved using traditional processes.

The continuous production of a liquid stream containing small curdparticles is taught in NZ 199366 in relation to the manufacture of milkbased foodstuffs including cheese and cheese-like products forincorporation as a raw material into processed foodstuffs.

The present invention uses the curd particles produced by the method ofNZ 199366 in combination with a heating and mechanical processing stepto produce natural cheeses including cheddar, cheddar-like, gouda,gouda-like mozzarella and mozzarella-like (pizza) cheese for the firsttime. In addition, the novel process allows for the control of thecharacteristics of the curd particles so that such cheeses have highermoisture and lower calcium content that the product produced by themethod of NZ 199366 alone.

The present invention provides a method of making cheese comprisingadding a coagulating agent to a pasteurised and standardised startingmilk and reacting at a temperature which suppresses the formation of acoagulum, passing the reacted mixture along a flow path while adjustingthe pH within a range between 4.0 to 6.0, and cooking said mixture at atemperature of up to 55° C. while inducing controlled turbulence in themixture to cause rapid coagulation and then disaggregation into smallcurd particles within the flow, separating the curd particles from thewhey liquid, heating and mechanically working the curd into a cheesemass at a curd temperature of 50 to 90° C., shaping and cooling thecheese mass.

The curd may be made into a final cheese product immediately while stillfresh, or may be frozen and/or dried, and thawed and/or reconstitutedbefore making into cheese.

Preferably, the invention provides a process of making cheese comprisingsteps of:

-   -   a. providing a starting milk composition having a fat content of        at least 0.05%;    -   b. optionally pasteurising and/or acidifying the milk        composition of step (a) to pH 6.0 to 6.5;    -   c. adding a coagulating agent to the starting milk composition        and reacting preferably for up to 20 hours at a temperature        which suppresses the formation of a coagulum;    -   d. optionally adjusting the pH of the reacted milk between pH        4.0 and 6.0;    -   e. cooking the milk composition under conditions which allows        the formation of coagulated curd particles;    -   f. separating the whey from the curd particles;    -   g. optionally washing the curd particles of step (f)    -   h. optionally freezing and/or drying the curd particles;    -   i. heating and mechanically working the fresh curd particles of        steps (f) or (g) or thawed and/or reconstituted curd particles        of step (h), at a curd temperature of 50° C. to 90° C.; and    -   j. shaping and cooling the cheese mass.

The general steps of this preferred process are set out in FIG. 1 andmay be carried out in any suitable order as would be appreciated by askilled worker. Preferably steps (a) to (j) of the process are performedin the recited order.

The cheese made by this process may comprise a soft, semi-soft, hard orextra hard cheese including cheddar, cheddar-like cheese, gouda,gouda-like cheese, mozzarella and mozzarella-like cheese.

The starting milk may be selected from one or more of the groupcomprising whole fat milk; whole milk retentate/concentrate; semiskimmed milk; skimmed milk; skimmed retentate/concentrate; butter milk;butter milk retentate/concentrate and whey protein retentate/concentrateor from products made from milk as would be appreciated by a personskilled in the art. One or more powders, such as whole milk powder,skimmed milk powder, milk protein concentrate powder, whey proteinconcentrate powder, whey protein isolate powder and buttermilk powder orother powders made from milk, reconstituted or dry, singularly or incombination may also be selected as the starting milk or be added to thestarting milk.

The starting milk may be sourced from any milk producing animal.

The protein and fat composition of the starting milk composition may bealtered by a process known as standardisation. The process ofstandardisation involves removing the variability in the fat and proteincomposition of the starting milk to achieve a particular end cheesecomposition. Traditionally, standardisation of milk has been achieved byremoving nearly all the fat (cream) from the starting milk (separation)and adding back a known amount of cream thereto to achieve apredetermined protein/fat ratio in the starting milk. The amount of fat(cream) required to be removed will depend upon the fat content of thestarting milk and the required end cheese composition. Preferably, thestarting milk has a fat content of at least 0.05%. If higher fatcontents are required a separate side stream of cream may be added toraise the fat content of the starting milk or the final cheese productas would be appreciated by a skilled worker. Additionally oralternatively, the protein concentration may be altered by adding aprotein concentrate such as a UF retentate or powder concentrate to astarting milk composition, or by any other method as would beappreciated by a person skilled in the art.

Pasteurisation may be carried out on any liquid stream at any stage ofthe process and in particular the starting milk and cream streams understandard condition as is known in the art. Optionally the cream ishomogenised.

Optionally the starting milk may be preacidified using any food approvedacidulent to preferably a pH of 6.0 and 6.5.

The coagulating agent is added to the standardised starting milk and themixture agitated to distribute the agent. The starting milk composition,containing coagulating agent is reacted under conditions which will notallow the formation of a coagulum, typically at a temperature of <22°C., preferably 8 to 10° C., at a suitable concentration of enzyme forsufficient time to react with the kappa casein. Typically, this reactionperiod is for 3 to 20 hours. This process is known as “cold setting” or“cold rennetting”. In particular, the coagulating agent is held in thestarting milk for a sufficient time to allow the enzyme to cleave thebond of kappa-casein and expose the casein micelle. This starting milkwould coagulate but for the temperature control of the reaction mixture.

Preferably the coagulating agent is an enzyme, and preferably the enzymeis chymosin (rennet). Sufficient coagulating agent is added to thestarting milk so that the cheese milk will coagulate at the cookingstep. For chymosin (rennet), this concentration ranges from 1 partrennet to 5,000 parts starting milk and 1 part rennet to 50,000 partsstarting milk. A more preferred rennet concentration is between 1 partto 15,000 starting milk and 1 part to 20,000 starting milk.

At this stage the milk composition is pumped through a plant andsubjected to in-line treatment.

After reacting with the coagulating agent, the pH of the milkcomposition (the “reacted milk”) is adjusted, if necessary, to pH 4.0 to6.0 preferably 5.2 to 6.0 by the addition of an acidulent.

Preferably the acidulent is a food grade acid such as lactic acid,acetic acid, hydrochloric acid, citric acid or sulphuric acid and isdiluted with water to approximately 1 to 20% w/w and then added to thereacted milk. More preferably, strong acids such as hydrochloric acid,are diluted to 2 to 5% w/w and weak acids such as lactic acid diluted to10 to 15% w/w before adding to the reacted milk. The acidulent may bedosed in-line, directly into the reacted milk to reduce the pH to thedesired pH.

Alternatively, the acidulent may comprise a growth medium which has beeninoculated with a starter culture and reacted to form a fermentate.

Pasteurised skimmilk is a preferred growth medium. Fermentation may beinduced by adding a starter culture to the growth medium and holding ata suitable temperature for a suitable time for the generation of acid tolower the pH to a level of between pH 4.0 and pH 6.0, preferably pH 4.6.

The starter culture to be added to the pasteurised growth medium streamcan be mesophilic or thermophilic or a mix and added at 0.0005 to 5%,preferably 0.01 to 0.2%, most preferably 0.1% of the milk volume.Examples of starter cultures are: Streptococcus thermophilus,Lactobacillus bulgaricus, Lactobacillus helveticus, Lactococcus lactissubspecies cremoris, Lactococcus lactis subspecies lactis.

Once the fermentate stream has reached the target pH, the fermentate canbe mixed in-line with the reacted milk. Where the two streams arecombined, a further step of mixing and holding the two streams isrequired, typically for 1 to 20 minutes to ensure that, where thefermentate comprises a milk based medium, such as skimmilk, thecoagulating agent in the reacted milk has time to act on the kappacasein in the fermentate. Optionally, the fermentate may be cooled andheld for subsequent use.

Optionally a combination of food grade acid and fermentate may be usedto acidify the reacted milk.

Once the fermentate and/or food grade acid (if required) have been addedand mixed by the liquid flow or using mechanical mixers such as anin-line static mixer, and held at the target pH, the milk composition isheated/cooked preferably to a temperature of 30 to 55° C. by usingdirect or indirect heating means to coagulate the protein and formcoagulated curd particles. In the case of direct heating, steam can beinjected into the liquid milk composition flow and in the case ofindirect heating, a jacketed heater or heat exchanger is associated withthe pipe along which the liquid is being pumped. The final temperaturereached by the curd mixture is determined by the properties required inthe final cheese curd. For example to decrease the moisture retained inthe curd the cook temperature is raised. In a preferred embodiment theflow velocity during cooling is high enough to ensure turbulence in theliquid mixture being passed there along. This enables the proteincoagulum to fragment into small relatively uniform curd particles andsyneresis commences. Preferably, the resulting curd particles arebetween 0.5 cm and 2 cm.

It is necessary to allow time for the syneresis to proceed. Preferablythe holding time in the cooking tube is 10 to 50 seconds at the desiredfinal cooking temperature and the flow is laminar. The cooked mixture ispassed to a separator to separate the curds from the whey. Theseparation may be achieved by any physical means, preferably by sieve ordecanter. Optionally, after separation of the curd, the curd may bewashed in water. In a preferred embodiment the pH of the water may beadjusted and the washing system may consist of a set of holding tubes.At the end of the holding tubes the washed curd may be separated by anyphysical means, preferably by sieve or decanter.

A reduction of the pH in the wash water results in solubilisation andremoval of calcium from the curd. A preferred embodiment is washingunder turbulent conditions with heated water at between 30 and 90° C. atpH 3.0 to 5.4.

Mineral adjustment, and particularly calcium adjustment, is a criticalstep in the cheesemaking process as the calcium content of the endcheese product affects its functionality and compositionalcharacteristics. The pH of the acidulent, the pH target of theacidulated enzyme treated mixture, the cooking temperature and the pH ofthe wash water (if used) are all steps in this process where calciumsolubilisation can be controlled. Surprisingly, the present inventionallows a cheese product to be produced with a significantly lowercalcium content than can be achieved using a traditional cheese makingprocess.

The removal of whey and subsequent wash water is referred to in the artas dewheying and dewatering. Optionally the dewheyed/dewatered curd maybe frozen and held for future use. In a further option thedewheyed/dewatered curd may be dried. In a further option thedewheyed/dewatered curd may be allowed to cheddar into a cohesive massof curd. Cheddaring is known in the art of cheesemaking. The cheddaredcurd is subsequently milled into particles and optionally salted.

In more traditional cheese making processes all the salt or a portion ofthe salt is added at this point or none at all. If salt is added aftermilling, time is allowed for the salt to penetrate the curd (mellowing).

In the next stage of the process the curd particles are converted into acheese mass by fusing them together by mechanically working and heatingat a suitable temperature. In a preferred embodiment a heated mixingdevice is used to fuse the curd particles. A time of 1 to 30 minutes isrequired to conduct the mixing and heating procedure to attain ahomogenous cheese mass. About 8 to 12 minutes are preferred.

The heating and mechanical working (stretching) step takes place at acurd temperature of between about 50° C. and 90° C. and may occur byimmersing the curd in hot water or hot whey as in a traditionalmozzarella cheese making method, or this step may take place in a dryenvironment as described in U.S. Pat. No. 5,925,398 and U.S. Pat. No.6,319,526. In either method, the curd is heated and worked into ahomogenous, plastic mass. Preferably the curd is heated to a curdtemperature of between about 50° C. to 75° C. using equipment common inthe art, such as a single or twin screw stretcher/extruder type deviceor steam jacketed and/or infusion vessels equipped with mechanicalagitators (waterless cookers).

Optionally cream, high fat cream or milk fat, water, whey proteinretentate or whey protein concentrate or salt may be added to the curdduring this mixing step. When cream is added, the cream is preferablyhomogenised.

The hot cheese mass may be immediately extruded into moulds or hoops andthe cheese cooled by spraying chilled water/brine onto the surface ofthe hoops as in traditional mozzarella cheese making processes. Thisinitial cooling step hardens the outside surface of the block providingsome rigidity. Following this initial cooling the cheese is removed fromthe moulds and placed in a salt brine (partially or completelysaturated) bath for a period of time to completely cool the cheese andenable uptake of the salt to the required level. Once cooled the cheeseis placed in plastic liners, air removed and the bag is sealedAlternatively, the hot cheese mass may be extruded into sheet-like orribbon-like form and directly cooled without moulding.

An alternative process sometimes used in commercial practice is tocompletely dry salt the cheese curd, mellow, heat work and pack directlyinto plastic liners contained in hoops and the liners sealed. The hoopsplus cheese are then immersed in chilled water.

Cooled cheese is stored at between 2° C. to 10° C. Once ready for usethe cheese may be used directly or the block frozen or the blockshredded and the shreds frozen.

Where the hot cheese mass is extruded as a ribbon or sheet, whichprovides rapid cooling, shredding and freezing of the shreds may takeplace in-line, immediately following cooling.

Other GRAS (generally accepted as safe) ingredients common to the cheesemaking process may be added at any suitable step in the process as wouldbe appreciated by a person skilled in the art. GRAS ingredients includenon-dairy ingredients such as stabilisers, emulsifiers, natural orartificial flavours, colours, starches, water, gums, lipases, proteases,mineral and organic acid, structural protein (soy protein or wheatprotein), and anti microbial agents as well as dairy ingredients whichmay enhance flavour and change the protein to fat ratio of the finalcheese. In particular, flavour ingredients may comprise variousfermentation and/or enzyme derived products or mixtures thereof as wouldbe appreciated by a skilled worker. Preferably, such GRAS ingredientsmay be added after the curd has been milled and/or during the “dry”mechanical working step; and/or to the extruded sheet-like orribbon-like hot stretched curd; and mixed or worked into the curd todisperse evenly. Alternatively, GRAS ingredients may be added to thestarting milk, during in-line acidification, or to the separatedcoagulated curd particles as would be understood by a skilled worker.The flexibility of allowing any combination of additives to be added atany step in the process allows the final composition of the cheese to beprecisely controlled, including the functionality characteristics.

In a further embodiment, the present invention provides a soft,semi-soft, hard or extra hard cheese product produced by the processesof the invention.

In a further embodiment, the present invention provides a mozzarella ormozzarella-like (pizza) cheese product produced by the processes of theinvention.

The present invention also provides a food product comprising themozzarella or mozzarella-like (pizza) cheese of the present invention,such as a pizza.

Any ranges mentioned in this patent specification are intended toinherently include all of the possible values within the stated range.

This invention may also be said broadly to consist in the parts,elements and features referred to or indicated in the specification ofthe application, individually or collectively, and any or allcombinations of any two or more of said parts, elements or features, andwhere specific integers are mentioned herein which have knownequivalents in the art to which this invention relates, such knownequivalents are deemed to be incorporated herein as if individually setforth.

The invention consists in the foregoing and also envisages constructionsof which the following gives examples.

EXAMPLE 1

Approximately 1800 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (100 ml). The renneted milk was left tostand overnight for approximately 16 hours at 10° C. Dilute sulphuricacid was then added to the cold renneted milk, in-line immediately priorto cooking, to reduce the pH to pH 5.4. The mixture was heated by directsteam injection at 42 to 44° C. and held for 50 seconds in holding tube.The coagulated cooked curd particles were separated from the whey usinga screen, washed using acidified water (8.3 L water, pH 2.6, dilutesulphuric acid/1 kg curd) and separated from the wash water using adecanter. After dewatering the curd was frozen for later use.

On thawing the aggregated curd was milled and partially dried using aring drier to 48% moisture. Salt (0.2 kg), high fat cream (7 kg), 0.272kg of lactic acid (16% solution) and flavours were added to 7 kg ofmilled and partially dried curd.

The flavours comprised a mixture of pre-prepared concentratedfermentation and enzyme-derived flavour ingredients [1.5% Alaco EMC(DairyConcepts, USA), 350 ppm Butyric acid and 16 mM acetate in finalproduct (Bronson & Jacobs Ltd, NZ)].

The curd and added ingredients were blended in a twin screw augerblender/cooker (Blentech Kettle, model CL0045, Twin screwcooker 1994,Rohnert Park, Calif., United States of America) for approximately 30seconds at 50 rpm. Speed of mixing was increased to 90 rpm and directsteam injection applied to bring the temperature of the mixture to 50°C. Mixing speed was then further increased to 150 rpm and thetemperature raised to approximately 68° C. Once at approximately 68° C.the now molten curd mixture was worked at 150 rpm for a further 1minute.

The molten curd was held for 1 to 3 minutes and then packaged into 0.5kg pottles and the pottles were air cooled for >12 hours toapproximately 5° C.

After 1 month storage this cheese had a firm texture and exhibited acheesy-cheddar-like flavour.

The final cheese composition was 35.0% fat, 38.5% moisture, 1.84% salt,pH 5.44 and a calcium level of 101 mmol Ca/kg cheese.

EXAMPLE 2

Approximately 1800 L of skimmilk was pasteurized and then cooled to 10°C. before rennet was added (100 ml). The renneted milk was left to standovernight approximately 16 hours at 10° C. Dilute sulphuric acid wasthen added to the cold renneted milk, in-line immediately prior tocooking, to reduce the pH to pH 5.4, and the mixture heated by directsteam injection at 42 to 44° C. and held for 50 seconds in a holdingtube. The coagulated curd particles were separated from the whey using ascreen, washed using acidified water (8.3 L water, pH 2.6, dilutesulphuric acid/1 kg curd) and separated from the wash water using adecanter. After dewatering the curd was frozen for later use.

On thawing the coagulated curd was milled and partially dried using aring drier to 49% moisture. Salt (0.265 kg), high fat cream (6.25 kg),0.272 kg of lactic acid (16% solution) and flavours were added to 7 kgof milled and partially dried curd.

The flavours comprised prepared concentrated fermentation andenzyme-derived flavour ingredients [50 ppm Butyric acid, 8 mM acetateand 2.5 ppm diacetyl in final product (Bronson and Jacobs Ltd, NZ) and 1ppm Lactone].

The curd and added ingredients were blended and heated according to theprocedure given in Example 1.

The molten curd was packaged into 0.5 kg pottles and the pottles wereair cooled for >12 hours.

Following cooling the curd was analysed for moisture, fat, salt and pH.

After 1 month storage this cheese had a firm texture and exhibited asweet Gouda-like flavour.

The final cheese composition was 35.5% fat, 39.1% moisture, 1.81% salt,pH 5.51 and a calcium level of 54 mmol Ca/kg cheese.

EXAMPLE 3

Approximately 1800 L of skimmilk was pasteurised and then cooled to 8 to10° C. before rennet was added (100 ml, i.e. 55 ml/1000 L). The rennetedmilk was left to stand for approximately 16 hours at 8 to 10° C. After16 hours dilute sulphuric acid was added to the cold renneted milk,in-line immediately prior to cooking, to reduce the pH to pH 5.3 and themixture heated by direct steam injection at 42° C. and held for 50seconds in a holding tube.

The coagulated curd particles were separated from the whey using ascreen and washed using acidified water (8.3 L water, pH 2.6, dilutesulphuric acid/1 kg curd). The washed coagulated curd particles, with amoisture content of about 52%, were separated from the wash water usinga decanter. After dewatering the curd was milled. Salt (0.2 kg), water(2.0 kg) and high fat cream (4.0 kg) were added to 7 kg of milled curd.

The curd and ingredients were blended according to the procedure givenin Example 1, with the exception that the final temperature was 72° C.

The molten curd was packaged into 0.5 kg pottles and the pottles wereair (<10° C.) for >12 hours.

Following cooling the curd was analysed for moisture, fat, salt and pH.

The final cheese composition was 21.0% fat, 53.7% moisture, 1.42% salt,pH 5.42 and a calcium level of 61 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days following manufacture pizzas were made toevaluate cheese functionality. Cheese made by this process showedsimilar functional properties in terms of blister size, coverage andcolour, background colour, melt appearance, oil off, stretchcharacteristics and in-mouth tenderness as a conventionally mademozzarella cheese.

EXAMPLE 4

Approximately 1200 L of reconstituted skimmilk powder (8.3% solids) waspasteurized and then cooled to 8 to 10° C. before rennet was added (66ml). The renneted milk was subsequently acidified with diluted sulphuricacid (2.5% w/w), cooked (42 to 45° C.) and the coagulated curd separatedand washed as outlined in Example 3

Salt (0.2 kg), water (1.8 kg), lactic acid (0.272 kg of a 16% solution)and high fat cream (4.0 kg) were added to 7 kg of milled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated to ≈72° C. and packed and stored under chilledconditions as outlined in Example 3.

The final cheese composition was 21.5% fat, 52.9% moisture, 1.40% salt,pH 5.80 and a calcium level of 106 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days following manufacture pizzas were made toevaluate cheese functionality. Cheese made by this process showedsimilar functional properties in terms of blister size, coverage andcolour, background colour, melt appearance, oil off, stretchcharacteristics and in-mouth tenderness as a conventionally mademozzarella cheese.

EXAMPLE 5

Approximately 2250 L of skimmilk was pasteurised and then cooled to 15°C. before a microbial enzyme Fromase 45TL (DMS Food Specialities, NSW,Australia) was added (200 ml). The Fromase treated milk was left tostand for approximately 3 hours at 15° C. After 3 hours dilute sulphuricacid was added to the cold renneted milk, in-line immediately prior tocooking at 45° C., to reduce the pH to pH 5.35. The cooking and washingprocess used was as outlined in Example 3.

The coagulated curd particles with a moisture content of about 53% wereseparated from the wash water using a decanter. After dewateringseparation the curd was milled. Salt (0.2 kg), water (2.0 kg) and highfat cream (4.0 kg) were added to 7 kg of milled curd. The curd andingredients were blended in a twin screw auger blender/cooker, heated to≈72° C. and packed and stored under chilled conditions as outlined inExample 3. The final cheese composition was 20.5% fat, 55.6% moisture,1.42% salt, pH. 5.97 and a calcium level of 93 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days following manufacture pizzas made to evaluatecheese functionality. Cheese made by this process showed similarfunctional properties in terms of blister size, coverage and colour,background colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

EXAMPLE 6

Approximately 450 L of skimmilk was pasteurised and then cooled to 7° C.before a microbial enzyme Fromase 45TL (DMS Food Specialities, NSW,Australia) was added (40 ml). The Fromase treated milk was left to standfor approximately 3 hours at 7° C. After 3 hours dilute sulphuric acidwas added to the cold renneted milk, in-line immediately prior tocooking at 50° C., to reduce the pH to pH 5.35. The cooking and washingprocess used was as outlined in Example 3.

The coagulated curd particles with a moisture content of about 53% wereseparated from the wash water using a decanter. After dewateringseparation the curd was milled.

Salt (0.2 kg), water (2.0 kg) and high fat cream (4.0 kg) were added to7 kg of milled curd. The curd and ingredients were blended in a twinscrew auger blender/cooker, heated to ≈72° C. and packed and storedunder chilled conditions as outlined in Example 3.

The final cheese composition was 21% fat, 55.0% moisture, 1.44% salt,pH. 5.98 and a calcium level of 92 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days pizzas were made to evaluate cheesefunctionality. Cheese made by this process showed similar functionalproperties in terms of blister size, coverage and colour, backgroundcolour, melt appearance, oil off, stretch characteristics and in-mouthtenderness as a conventionally made mozzarella cheese.

EXAMPLE 7

Approximately 450 L of skimmilk was pasteurised and then cooled to 7° C.before a microbial enzyme Fromase 45TL (DMS Food Specialities, NSW,Australia) was added (40 ml). The Fromase treated milk was left to standfor approximately 3 hours at 7° C. After 3 hours dilute sulphuric acidwas added to the cold renneted milk, in-line immediately prior tocooking at 38° C., to reduce the pH to pH 5.35. The cooking process usedwas as outlined in Example 3. Washing was not carried out.

The coagulated curd particles with a moisture content of about 54% wereseparated from the whey using a decanter. After whey separation the curdwas milled. Salt (0.2 kg), water (2.0 kg) and high fat cream (4.0 kg)were added to 7 kg of milled curd. The curd and ingredients were blendedin a twin screw auger blender/cooker, heated to ≈72° C. and packed andstored under chilled conditions as outlined in Example 3. The finalcheese composition was 23% fat, 50% moisture, 1.61% salt, pH. 5.87 and acalcium level of 115 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made by this process showed similarfunctional properties in terms of blister size, coverage and colourbackground colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

EXAMPLE 8

Approximately 2250 L of skimmilk was pasteurized and cooled to 8 to 10°C. and rennet was added (125 ml, i.e. 55 ml/1000 L). The renneted milkwas left to stand overnight for approximately 16 hours at 8 to 10° C. Asecond milk stream comprising 900 L of skimmilk and a lactic acidculture (Lactococcus lactis subspecies cremoris) was prepared and alsoleft to stand overnight for approximately 16 hours at 26° C. to reducethe pH of the milk to pH 4.6. The second milk stream was then added tothe cold renneted milk and mixed. The pH of the mixture was 5.3. Themixture was then cooked using direct steam injection at 48° C. and heldfor 50 seconds in a holding tube. The coagulated curd particles wereseparated from the whey using a screen and washed using acidified water(8.3 L water, pH 2.6, dilute sulphuric acid/1 kg curd). The washed,coagulated curd with a moisture content of about 53% was separated fromthe wash water using a decanter, milled and salted. Salt (0.2 kg), water(1.4 kg) and high fat cream (4 kg) were added to 7 kg of milled curd.The curd and added ingredients were blended in a twin screw augerblender/cooker, heated to ≈62° C. and packed and stored under chilledconditions as outlined in Example 3.

The final cheese composition was 22.2% fat, 54.3% moisture, 1.50% salt,pH 5.09, and a calcium level of 53 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made by this process showed similarfunctional properties in terms of blister size, coverage and colour,background colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

In the ensuing examples, the coagulated curd particles were separatedfrom the whey using a screen and washed using acidified water (8.3 Lwater, pH 2.6, dilute sulphuric acid/1 kg curd). The washed, coagulatedcurd was separated from the wash water using a decanter and typicallyhad a moisture content of between 52 and 54% w/w.

EXAMPLE 9

Approximately 600 L of skimmilk was pasteurised and then cooled to 8 to10° C. before rennet was added (33 ml). The renneted milk was left tostand for approximately 16 hours at 8 to 10° C. After 16 hours dilutelactic acid (0.25 M) was added to the cold renneted milk, in-lineimmediately prior to cooking at 42 to 45° C., to reduce the pH to pH5.35. The cooking and washing process used was as outlined in Example 3.

After dewatering the curd was milled and salted. Salt (0.2 kg), water(1.9 kg) and high fat cream (4.0 kg) and Lactic acid (0.272 kg of a 16%solution) were added to 7 kg of milled curd. The curd and ingredientswere blended in a twin screw auger blender/cooker, heated to ≈60° C. andpacked and stored under chilled conditions as outlined in Example 3.

The final cheese composition was 20.5% fat, 54.3% moisture, 1.37% salt,pH. 5.64 and a calcium level of 93 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made by this process similar functionalproperties in terms of blister size, coverage and colour, backgroundcolour, melt appearance, oil off, stretch characteristics and in-mouthtenderness as a conventionally made mozzarella cheese.

EXAMPLE 10

Approximately 600 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (33 ml). The renneted milk was left tostand overnight approximately 16 hours at 8 to 10° C. Dilute acetic acid(0.25 M) was then added to the cold renneted milk, in-line immediatelyprior to cooling at 42 to 45° C., to reduce the pH to pH 5.35. Thecooking and washing process used was as outlined in Example 3.

After dewatering the curd was milled and salted. Salt (0.2 kg), water(1.9 kg), high fat cream (4.0 kg), lactic acid (0.272 kg of a 16%solution) were added to 7 kg of milled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated and to ≈65° C. and packed and stored underchilled conditions as outlined in Example 3.

The final cheese composition was 20.5% fat, 54.1% moisture, 1.39% salt,pH 5.64 and a calcium level of 101 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made by this process showed similarfunctional properties in terms of blister size, coverage and colour,background colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

EXAMPLE 11

Approximately 600 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (33 ml). The renneted milk was left tostand overnight approximately 16 hours at 8 to 10° C. Dilutehydrochloric acid (0.25 M) was then added to the cold renneted milk,in-line immediately prior to cooking at 42 to 45° C., to reduce the pHto pH 5.35. The cooking and washing process used was as outlined inExample 3.

After dewatering the curd was milled. Salt (0.2 kg), water (1.9 kg),high fat cream (4.0 kg), lactic acid (0.272 kg of a 16% solution) wereadded to 7 kg of milled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated to ≈65° C. and packed and stored under chilledconditions as outlined in Example 3.

The final cheese composition was 21.0% fat, 53.3% moisture, 1.41% salt,pH 5.64 and a calcium level of 99 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made by this process showed similarfunctional properties in terms of blister size, coverage and colour,background colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

EXAMPLE 12

Approximately 600 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (33 ml). The renneted milk was left tostand overnight approximately 16 hours at 8 to 10° C. Dilute sulphuricacid (0.25 M) was then added to the cold renneted milk, in-lineimmediately prior to cooling at 42 to 45° C., to reduce the pH to pH5.35. The cooking and washing process used was as outlined in Example 3.

After dewatering the curd was milled. Salt (0.2 kg), high fat cream (4.0kg) and lactic acid (0.272 kg of a 16% solution) were added to 7 kg ofmilled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated to ≈65° C. and worked as outlined in Example 3

Once at approximately 65° C. water (0.95 kg) was added and the nowmolten curd mixture was worked at 150 rpm for a further 1 minute.

The molten curd was then packed and stored under chilled conditions asoutlined in Example 3.

The final cheese composition was 21.0% fat, 54.0% moisture, 1.39% salt,pH 5.52 and a calcium level of 91 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made by this process showed similarfunctional properties in terms of blister size, coverage and colour,background colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

EXAMPLE 13

Approximately 2250 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (125 ml). The renneted milk was left tostand overnight approximately 16 hours at 8 to 10° C. Dilute sulphuricacid (0.25 M) was then added to the cold renneted milk, in-lineimmediately prior to cooking at 42 to 45° C., to reduce the pH to pH5.35. The cooking and washing process used was as outlined in Example 3

After dewatering the curd was milled. Salt (0.18 kg), emulsificationsalts (0.035 kg trisodium citrate), water (2.4 kg), high fat cream (4.15kg) and lactic acid (0.272 kg of a 16% solution) were added to 7 kg ofmilled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated to ≈65° C. and packed and stored under chilledconditions as outline in Example 3.

The final cheese composition was 21.0% fat, 54.5% moisture, 1.24% salt,pH 5.84 and a calcium level of 91 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made by this process showed similarfunctional properties in terms of blister size, coverage and colour,background colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

EXAMPLE 14

Approximately 2250 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (125 ml). The renneted milk was left tostand overnight approximately 16 hours at 8 to 10° C. Dilute sulphuricacid (0.25 m) was then added to the cold renneted milk, in-lineimmediately prior to cooking at 42 to 45° C., to reduce the pH to pH5.35. The cooking and washing process used was as outlined in Example 3.

After dewatering the curd was milled. Salt (0.22 kg), gums (1.4 kg of anaqueous 10% kappa carrageenan solution), water (1.3 kg), high fat cream(4.0 kg) and lactic acid (0.272 kg of a 16% solution) were added to 7 kgof milled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated to ≈65° C. and packed and stored under chilledconditions as outlined in Example 3.

The final cheese composition was 21.5% fat, 53.3% moisture, 1.61% saltand pH 5.78 and a calcium level of 98 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made by this process showed similarfunctional properties in terms of blister size, coverage and colourbackground colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

EXAMPLE 15

Approximately 2250 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (125 ml). The renneted milk was left tostand overnight approximately 16 hours at 8 to 10° C. Dilute sulphuricacid (0.25 m) was then added to the cold renneted milk, in-lineimmediately prior to cooking at 42 to 45° C., to reduce the pH to pH5.35. The cooking and washing process used was as outlined in Example 3.

After dewatering the curd was milled. Salt (0.21 kg), whey proteinconcentrate (cheese whey derived with 80% protein) derived from cheesewhey (0.385 kg of an aqueous 20% solution), water (2.15 kg), high fatcream (4.15 kg) and lactic acid (0.272 kg of a 16% solution) were addedto 7 kg of milled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated at ≈65° C. and packed at stored under chilledconditions as outlined in Example 3.

The final cheese composition was 20.0% fat, 55.1% moisture, 1.40% salt,pH 5.82 and a calcium level of 92 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas made to evaluate cheesefunctionality. Cheese made by this process showed similar functionalproperties in terms of blister size, coverage and colour, backgroundcolour, melt appearance, oil off, stretch characteristics and in-mouthtenderness as a conventionally made mozzarella cheese.

EXAMPLE 16

Approximately 1800 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (100 ml). The renneted milk was left tostand overnight approximately 16 hours at 8 to 10° C. Dilute sulphuricacid was then added to the cold renneted milk, in-line immediately priorto cooking at 42 to 44° C., to reduce the pH to pH 5.3. The cooking andwashing process used was as outlined in Example 3.

After dewatering the curd was frozen for later use. On thawing theaggregated curd was milled. Water (1.8/kg), salt (0.2 kg), high fatcream (4 kg) and 0.272 kg of lactic acid (16% solution) were added to 7kg of milled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated to ≈68° C. and packed and stored under chilledconditions as outlined in Example 3.

The final cheese composition was 22.0% fat, 54.0% moisture, 1.41% salt,pH 5.38 and a calcium level of 73 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made by this process showed similarfunctional properties in terms of blister size, coverage and colour,background colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

EXAMPLE 17

Approximately 1800 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (100 ml). The renneted milk was left tostand overnight approximately 16 hours at 8 to 10° C. Dilute sulphuricacid was then added to the cold renneted milk, in-line immediately priorto cooking at 42 to 44° C., to reduce the pH to pH 5.3. The cooking andwashing process used was as outlined in Example 3.

After dewatering the curd was allowed to cheddar and frozen for lateruse. On thawing the cheddared curd was milled. Water (1.45 kg), salt(0.2 kg), high fat cream (3.5 kg) and 0.272 kg of lactic acid (16%solution) were added to 7 kg of milled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated to ≈68° C. and packed and stored under chilledconditions as outlined in Example 3.

The final cheese composition was 21.0% fat, 53.6% moisture, 1.49% salt,pH 5.31 and a calcium level of 63 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made by this process showed similarfunctional properties in terms of blister size, coverage and colour,background colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

EXAMPLE 18

Approximately 1800 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (100 ml). The renneted milk was left tostand overnight approximately 16 hours at 8 to 10° C. Dilute sulphuricacid was then added to the cold renneted milk, in-line immediately priorto cooking at 42 to 44° C., to reduce the pH to pH 5.3. The cooking andwashing process used was as outlined in Example 3.

After dewatering the curd was allowed to cheddar and frozen for lateruse. On thawing the cheddared curd was milled. Water (1.1 kg), salt (0.2kg), high fat cream (3.0 kg) and 0.272 kg of lactic acid (16% solution)were added to 7 kg of milled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated to ≈68° C. and packed and stored under chilledconditions as outlined in Example 3.

The final cheese composition was 19.5% fat, 53.3% moisture, 1.61% salt,pH 5.33, and a calcium level of 61 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made by this process showed similarfunctional properties in terms of blister size, coverage and colour,background colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

EXAMPLE 19

Approximately 1800 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (100 ml). The renneted milk was left tostand overnight approximately 16 hours at 8 to 10° C. Dilute sulphuricacid was then added to the cold renneted milk, in-line immediately priorto cooking at 42 to 44° C., to reduce the pH to pH 5.3. The cooking andwashing process used was as outlined in Example 3.

After dewatering the curd was allowed to cheddar and frozen for lateruse. On thawing the cheddared curd was milled. Water (0.75 kg), salt(0.165 kg), high fat cream (2.5 kg) and 0.272 kg of lactic acid (16%solution) were added to 7 kg of milled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated to 68° C. and packed and stored under chilledconditions as outlined in Example 3.

The final cheese composition was 17.0% fat, 53.5% moisture, 1.42% salt,pH 5.33 and a calcium level of 68 mmol/kg cheese.

The cheese made by this process was a mozzarella or mozzarella-likecheese. Within 10 days of manufacture pizzas were made to evaluatecheese functionality. Cheese made made by this process showed similarfunctional properties in terms of blister size, coverage and colour,background colour, melt appearance, oil off, stretch characteristics andin-mouth tenderness as a conventionally made mozzarella cheese.

EXAMPLE 20

Approximately 2200 L of skimmilk was pasteurized and then cooled to 8 to10° C. before rennet was added (120 ml). The renneted milk was left tostand overnight approximately 16 hours at 8 to 10° C. Dilute sulphuricacid was then added to the cold renneted milk, in-line immediately priorto cooking at 44° C., to reduce the pH to pH 5.3. The cooking andwashing process used was as outlined in Example 3.

After dewatering the curd was allowed to cheddar and was then chilledfor use 5 days later. When required the cheddared curd was milled. Water(3.1 kg), salt (0.69 kg), high fat cream (7.0 kg) and (0.035 kg) TriSodium Citrate were added to 12 kg of milled curd.

The curd and added ingredients were blended in a twin screw augerblender/cooker, heated to ≈68° C. as outlined in Example 3.

The 68° C. homogenous mass of curd was then placed in a dry, twin screwMozzarella pilot plant cooker/stretcher (in-house design) and pumpedthrough a (60 to 65° C.) jacketed, 10 barreled (16 mm×200 mm) Stringcheese extrusion head. The Mozzarella cooker/stretcher was used as apump to push the molten curd through the extrusion head.

Strings were cut into approximately 300 to 400 mm lengths and cooled inchilled water for approximately 10 to 15 minutes. On removal from thechilled water bath the lengths of String cheese were trimmed to 200 mm,laid on trays and blast frozen (−32° C.) for at least 1 hour.

The final String cheese composition was 20.5% fat, 54.1% moisture, 2.28%salt, pH 6.03 and a calcium level of 87 mmol/kg cheese.

The String cheese made by this process showed similar fibrous textureand flavour characteristics as those obtained in commercial Stringcheese made from Mozzarella curd.

INDUSTRIAL APPLICATION

The processes of the present invention and cheese made using theprocesses have commercial application in the cheese industry. Inparticular, mozzarella cheese made by this process has application inthe pizza making industry that utilises mozzarella and mozzarella-like(pizza) cheese in significant quantities.

It will be appreciated that it is not intended to limit the invention tothe above examples only, many variations, such as might readily occur toa person skilled in the art being possible without departing from thescope as defined in the appended claims.

1. A process of making cheese comprising steps of: a) adding acoagulating agent to a starting milk under conditions of temperaturetime and coagulating agent concentration, which suppresses the formationof a coagulum; b) passing the milk of step a) along a flow path andadjusting the pH where necessary to between 4.0 and 6.0 by adding anacidulent; c) cooking the milk of step b) at a temperature which allowsthe formation of coagulated curd particles within the flow; d)separating the coagulated curd particles from the whey liquid; e)heating and mechanically working the curd particles into a cheese massat a temperature of 50 to 90° C. in a substantially dry environment; andf) shaping and cooling the cheese.
 2. A process of making cheesecomprising steps of: a) providing a starting milk composition having afat content of at least 0.05%; b) optionally pasteurising the milkcomposition of step a; c) adding a coagulating agent to the startingmilk composition, and reacting under conditions of time, temperature andcoagulating agent concentration, which suppresses the formation of acoagulum; d) adding an acidulent to the milk composition to reduce thepH to a level of 4.0 to 6.0; e) cooking the milk composition underconditions which allow for the formation of coagulated curd particles;f) separating the curd particles from whey liquid; g) optionallyadjusting the mineral content of the curd particles; h) optionallyfreezing and/or drying the curd particles; i) heating and mechanicallyworking the fresh curd particles of step (f) or (g), or the thawedand/or reconstituted curd particles of step (h) at a curd temperature of50° C. to 90° C. into a cheese mass in a substantially dry environment;and j) shaping and cooling the cheese.
 3. The process of claim 1 whereinthe steps a to fare performed in the recited order.
 4. The process ofclaim 2, wherein the steps a to j are performed in the recited order,including steps b), g), and h).
 5. A process as claimed in claim 1,wherein the cheese comprises a soft, semi-soft, hard or extra hardcheese.
 6. A process as claimed in claim 5, wherein the cheese comprisescheddar, cheddar-like cheese, gouda, gouda-like cheese, mozzarella ormozzarella-like cheese.
 7. A process as claimed in claim 1, wherein thestarting milk is selected from the group consisting of whole fat milk;whole milk retentate/concentrate; semi skimmed milk; skimmed milk;skimmed milk retentate/concentrate, butter milk; butter milkretentate/concentrate; whey protein retentate/concentrate; milk powderand from any suitable product made from milk.
 8. A process as claimed inclaim 7, wherein said milk powder is selected from the group consistingof whole milk powder, skimmed milk powder, milk protein concentratepowder, whey protein concentrate powder, whey protein isolate powder andbuttermilk powder and other powder made from milk, and is used in areconstituted or dry form, singularly or in combination as the startingmilk or is added to the starting milk.
 9. A process as claimed in claim1, wherein the starting milk is sourced from any milk producing animal.10. A process as claimed in claim 1, wherein a further step ofstandardization to alter the fat and protein composition, is carried outon the starting milk before the addition of coagulating agent or afterthe curd particles have been separated and before the heating andmechanical working step.
 11. A process as claimed in claim 1, whereinthe coagulating agent is a coagulating enzyme selected from the groupconsisting of rennet/chymosin and other enzymes capable of convertingkappa-casein into para kappa-casein.
 12. A process as claimed in claim1, wherein the conditions which suppress the formation of a coagulumcomprise a temperature of less than 22° C. for 3 to 20 hours at acoagulating agent concentration which will allow coagulation at thecooking step.
 13. A process as claimed in claim 12, wherein theconditions which suppress the formulation of a coagulum comprise atemperature of between 8 and 10° C., for 16 hours at a coagulating agentconcentration which will allow coagulation at the cooling step.
 14. Aprocess as claimed in claim 1, wherein acidification is by the additionof an acidulent directly in-line to reduce the pH of the reacted milk tobetween pH 4.0 and 6.0.
 15. A process as claimed in claim 14, whereinthe acidulent is a food grade inorganic or organic acid selected fromsulfuric acid, lactic acid, acetic acid, hydrochloric acid and citricacid or a mixture or thereof.
 16. A process as claimed in claim 14,wherein the acidulent comprises a growth medium which has beeninoculated with a starter culture and reacted to form a fermentate. 17.A process as claimed in claim 16, wherein the starter culture added tothe growth medium is a mesophilic or thermophilic bacteria or a mixturethereof and is added at 0.0005 to 5% of the milk volume.
 18. A processas claimed in claim 17, wherein the starter culture is selected from thegroup comprising Streptococcus thermophilus, Lactobacillus bulgaricus,Lactobacillus helveticus, Lactococcus lactis subspecies cremoris,Lactococcus lactis subspecies lactis or any other suitable bacterium.19. A process as claimed in claim 16, wherein a fermentate is preparedby heating a growth medium selected from skim milk, skim milk retentate,reconstituted skim milk, or any other commercially available startermedium to a temperature optimal for the growth of the culture to begrown, adding the culture and allowing fermentation to proceed until thepH of the growth medium has reached a target pH of 4.0 to 6.0.
 20. Aprocess as claimed in claim 19, where the target pH is 4.5 to 6.0.
 21. Aprocess as claimed in claim 19, wherein once the fermentate has reachedits target pH it is added to the reacted milk, directly in-line and afurther step of mixing and holding is carried out.
 22. A process asclaimed in claim 14 wherein the pH of the reacted milk is reduced to pH5.2 to 6.0.
 23. A process as claimed in claim 1, wherein one or moreGRAS ingredients are added at any one or more of steps of the process.24. A process as claimed in claim 23, wherein one or more GRASingredients are added during the heating and mechanical working step.25. A process as claimed in claim 23, where one or more GRAS ingredientsare added during the shaping and cooling step.
 26. A process as claimedin claim 1, further comprising a step of washing the curd particlesafter separating from whey.
 27. A process as claimed in claim 26,wherein said washing step is carried out using water at a pH of 3.0 to5.4 to produce curd particles with a reduced calcium content.
 28. Aprocess as claimed in claim 2, wherein step g comprises a washing stepcarried out using water at a pH of 3.0 to 5.4 to produce curd particleswith a reduced calcium content.
 29. A process as claimed in claim 2,wherein the cheese comprises a soft, semi-soft, hard or extra hardcheese.
 30. A process as claimed in claim 2, wherein the starting milkis selected from the group consisting of whole fat milk; whole milkretentate/concentrate; semi skimmed milk; skimmed milk; skimmed milkretentate/concentrate, butter milk; butter milk retentate/concentrate;whey protein retentate/concentrate; milk powder and from any suitableproduct made from milk.
 31. A process as claimed in claim 2, wherein thestarting milk is sourced from any milk producing animal.
 32. A processas claimed in claim 2, wherein a further step of standardization toalter the fat and protein composition, is carried out on the startingmilk before the addition of coagulating agent or after the curdparticles have been separated and before the heating and mechanicalworking step.
 33. A process as claimed in claim 2, wherein thecoagulating agent is a coagulating enzyme selected from the groupconsisting of rennet/chymosin and other enzymes capable of convertingkappa-casein into para kappa-casein.
 34. A process as claimed in claim2, wherein the conditions which suppress the formation of a coagulumcomprise a temperature of less than 22° C. for 3 to 20 hours at acoagulating agent concentration which will allow coagulation at thecooking step.
 35. A process as claimed in claim 2, wherein acidificationis by the addition of an acidulent directly in-line to reduce the pH ofthe reacted milk to between pH 4.0 and 6.0.
 36. A process as claimed inclaim 20, wherein once the fermentate has reached its target pH it isadded to the reacted milk, directly in-line and a further step of mixingand holding is carried out.
 37. A process as claimed in claim 2, whereinone or more GRAS ingredients are added at anyone or more of steps of theprocess.
 38. A process as claimed in claim 37, wherein one or more GRASingredients are added during the heating and mechanical working step.39. A process as claimed in claim 37, where one or more GRAS ingredientsare added during the shaping and cooling step.
 40. A process as claimedin claim 23, wherein said washing step is carried out using water at apH of 3.0 to 5.4 to produce curd particles with a reduced calciumcontent.
 41. A process as claimed in claim 37, wherein said washing stepis carried out using water at a pH of 3.0 to 5.4 to produce curdparticles with a reduced calcium content.
 42. A process as claimed inclaim 2, further comprising a step of washing the curd particles afterseparating from whey.